Mounting boss for a brazed heat exchanger

ABSTRACT

A heat exchanger ( 10 ) includes a mount boss ( 12 ) fixed between a pair of adjacent tube runs ( 16 ) extending from a header ( 14 ). The mount boss ( 12 ) includes a pair of oppositely facing contoured surfaces ( 40 ) that are shaped to conform to the exterior surfaces of the adjacent tube runs ( 16 ).

FIELD OF THE INVENTION

This invention relates to heat exchangers, and more particularly to air cooled heat exchangers and the structure provided on such heat exchangers for mounting the heat exchangers in a system, such as in a vehicle.

BACKGROUND OF THE INVENTION

Air cooled heat exchangers are well known, and are commonly used in vehicular and other applications where there is a readily available flow of air. Such heat exchangers will typically have two or more manifolds or headers for distributing and collecting the working fluid (such as coolant, oil, or refrigerant) to and from the heat exchanger and a plurality of tube runs extending between the headers to direct the working fluid through the heat exchanger in heat exchange relation with an air flow passing over the exterior of the tube runs and fins that extend between the tube runs. It is common in such heat exchangers to provide a plurality of brackets fixed on the manifolds to act as structure for mounting the heat exchanger to the remainder of the system in which the heat exchanger is used. While such designs have proven suitable for their intended use, there is always room for improvement.

SUMMARY OF THE INVENTION

In accordance with one feature of the invention, a heat exchanger includes a header, a pair of tube runs extending from the header along a longitudinal tube axis to direct a fluid through the heat exchanger, and a mount boss fixed between the pair of tube runs. The mount boss has a pair of oppositely facing contoured surfaces, with each of the contoured surfaces being bonded to a mating surface of a corresponding one of the tube runs and shaped to conform to the mating surface.

As one feature, the mount boss is located adjacent the header and further includes a surface bonded to a mating surface of the header.

In a further feature, the surface bonded to the mating surface of the header is shaped to conform to the mating surface of the header.

In yet a further feature the mating surface of the header is cylindrical.

According to one feature, the mount boss further includes an opening adapted to receive a fastener.

In a further feature, the opening is threaded.

As one feature, the opening extends completely through the mount boss.

As a further feature, the opening extends perpendicular to the longitudinal tube axis.

According to one feature, each of the tube runs is a flattened tube having a transverse cross section defined by a pair of spaced, broad side walls connected by a pair of shorter end walls, and each of the contoured surfaces of the mount boss is bonded one of the broad side wall of one of the pair of tube runs.

In one feature, the heat exchanger further includes fins extending between the pair of tube runs.

According to one feature of the invention, a heat exchanger includes a header, a pair of tube runs extending from the header along a longitudinal tube axis to direct a fluid through the heat exchanger, and a mount boss fixed between the pair of tube runs. The mount boss has a pair of shoulders, with the shoulders abutting opposite sides of a corresponding one of the tube runs to locate the mount boss during a bonding process.

In one feature, each of the tube runs is a flattened tube having a transverse cross section defined by a pair of spaced, broad side walls connected by a pair of shorter end walls, and the mount boss has a pair of opposite sides, each of the opposite sides bonded to one of the broad side wall of one of the pair of tube runs.

According to one feature of the invention, a heat exchanger includes a pair of spaced headers, a plurality of tube runs extending between the headers along a longitudinal tube axis to direct a fluid through the heat exchanger, fins extending between the tube runs, and a mount boss fixed between an adjacent pair of the tube runs. The mount boss has a pair of oppositely facing contoured surfaces, with each of the contoured surfaces being bonded to a mating surface of a corresponding one of the tube runs and shaped to conform to the mating surface.

In accordance with one feature of the invention, a heat exchanger includes a pair of spaced headers, a plurality of tube runs extending between the headers along a longitudinal tube axis to direct a fluid through the heat exchanger, fins extending between the tube runs, and a mount boss fixed between an adjacent pair of tube runs. The mount boss has a pair of shoulders, with the shoulders abutting opposite sides of a corresponding one of the tube runs to locate the mount boss during a bonding process.

Other objects, features, and advantages of the invention will become apparent from a review of the entire specification, including the appended claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial, perspective view showing a portion of a heat exchanger including a mount structure embodying the present invention;

FIG. 2 is a view showing the mount structure of FIG. 1 together with a header and a pair of tube runs of FIG. 1;

FIG. 3 is a view taken from line 3-3 in FIG. 2;

FIG. 4 is a perspective view of the mount structure of FIGS. 1-3; and

FIG. 5 is a perspective view of an alternate embodiment of the mount boss.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, an air cooled heat exchanger 10 is shown and includes a mount structure in the form of a pair of mount components or bosses 12. The heat exchanger 10 is of a well-known construction, commonly referred to as a parallel flow (“PF”) type construction, that includes a pair of headers 14 (only one shown in FIG. 1) for directing the working fluid to and from the heat exchanger 10 and a plurality of tube runs 16 extending between the headers 14 to direct the working fluid through the heat exchanger 10 to and from the headers 14, with fins 18 extending between the tube runs to enhance the transfer of heat from the working fluid passing through the interior of the tube runs 16 to an air flow passing over the exterior of the tube runs 16 and through the fins 18. The tube runs 16 extend along a longitudinal tube axis 19 between each of the headers 14. While any suitable heat exchange tube construction can be used, in the illustrated embodiment, each of tube runs 16 is provided in the form of a single, flattened tube 20 having opposite ends 22 (only one shown in FIG. 1) connected to the corresponding header 14. As best seen in FIG. 2, each of the flattened tubes 20 has a transverse cross section defined by a pair of broad side walls 24 connected by a pair of shorter end or nose walls 26, with the broad side walls defining a major dimension of the tube and the nose walls 26 defining a minor dimension of the tube 20. While not shown, it may be preferred in some applications for the tubes to be so-called multi-port tube or microchannel tubes that are extruded. The fins 18 can be of any suitable form, such as plate fins, or corrugated or serpentine fins. Similarly, while each of the headers 14 may be of any suitable construction, including header plate/tank constructions, in the illustrated embodiment, each of the headers 14 is provided in the form of a cylindrical tube 30 that has tube receiving openings 32 sealingly receiving the ends 22 of the tubes 20.

As best seen in FIG. 1, each of the mount bosses 12 is fixed between a pair of the tube runs 16 adjacent the header 14. It should be appreciated that, in the preferred embodiment, a corresponding pair of mount bosses 12 are similarly located adjacent the other header 14 (not shown in FIG. 1) of the heat exchanger 10. It should also be appreciated that while only two of the mount bosses 12 are shown adjacent each of the headers 14, in some applications it may be desirable to provide more or fewer of the mount bosses 12, and/or for the location of the mount bosses 12 to be varied with respect to each of the headers 14 so that there is an unsymmetric pattern of the mount bosses 12.

With reference to FIGS. 2-4, it can be seen that each of the mount bosses 12 has a pair of oppositely facing contoured surfaces 40 that are bonded (such as by brazing) to the broad side walls 24 of the adjacent pair of tube runs 16 and are shaped to conform to the exterior surface 42 of the corresponding tube run 16. This helps to strengthen the bond connection or joint between the mount boss 12 and the adjacent tube run 16. It is also preferred that each of the surfaces 40 include a pair of shoulders 44 which abut the opposite nose walls 26 of the tube runs 16. This helps to maintain the mount boss 12 in its desired location during the bonding operation for the heat exchanger, which will typically be brazing.

With reference to FIG. 3, it is also preferred that the mount bosses 12 include another surface 46 that abuts and is bonded to the exterior surface 47 of the header 14. In this regard, it may be desirable in some applications for the surface 46 to also be a contoured surface that is shaped to conform to the exterior surface 47 of the header 14, as seen by the alternate embodiment illustrated in FIG. 5.

Each of the bosses 12 further includes an opening 48 to receive a fastener of the mating support structure of the system in which the heat exchanger 10 is used. In this regard, the opening 48 can be a threaded opening to receive a threaded fastener 49 such as is shown in FIG. 1, or can be an unthreaded opening designed to allow a shoulder bolt, mount stud, or other similar structure (not shown) to pass through the boss 12. Preferably, as best seen in FIG. 2, each boss 12 includes a front face 50 and a back face 52, with the front and back faces 50,52 being spaced from each other by a distance W_(B) that is no greater than the depth dimension W_(H) of the corresponding header 14, which in the illustrated embodiment would be equivalent to the diameter of the tube 30. This serves to minimize the overall depth of the heat exchanger 10. However, in some applications it may be desirable for W_(B) to be greater than W_(H).

Preferably, each of the mount bosses 12 is formed from a single, unitary block of suitable material, and in the preferred embodiment will be formed from a block of aluminum, with the remaining components of the heat exchanger 10 also being formed from suitable material, preferably aluminum, with a suitable braze clad being provided where appropriate, such as on the exterior surfaces 42 of the tube runs 16 and the exterior surface 47 of the headers 14 to allow for brazing, such as a controlled atmosphere brazing. (CAB) in a furnace, to metallically bond the components, including the bosses 12, of the heat exchanger 10.

It should be appreciated that while the mount bosses 12 have been illustrated in connection with the heat exchanger 10 utilizing flattened tubes 20, in some applications it may be desirable to utilize the mount bosses 12 in connection with a heat exchanger 10 having tube runs 16 of a different cross section, such as round tubes. Furthermore, while the mount bosses 12 are illustrated as having a generally rectangular transverse cross section, it may be desirable in some applications for the mount bosses 40 to have a different general transverse cross-sectional shape, such as, for example, circular. Also, while it is preferred for the mount bosses 12 to be mounted adjacent the headers 14, in some applications it may be desirable for the mount bosses 12 to be spaced from the headers 14. Furthermore, it should be appreciated that in addition to serving as mount structure for mounting the heat exchanger 10 to the remainder of the system, the mount bosses 12 may also be used to mount other components to the heat exchanger 10.

It should be appreciated that by providing suitable locating features, such as the shoulders 44 and/or the contoured surfaces 40, the mount bosses 12 can be assembled to the remainder of the heat exchanger 10 without the need for tack welding or the use of fixtures to hold the bosses 12 in place during the desired brazing operation. It should also be appreciated that by contouring the surfaces 40 to conform to the exteriors of the adjacent tube runs 16, the structural strength associated with the mount bosses 12 is enhanced. 

1. A heat exchanger comprising: a header; a pair of tube runs extending from the header along a longitudinal tube axis to direct a fluid through the heat exchanger; and a mount boss fixed between the pair of tube runs, the mount boss having a pair of oppositely facing contoured surfaces, each of the contoured surfaces bonded to a mating surface of a corresponding one of the tube runs and shaped to conform to the mating surface.
 2. The heat exchanger of claim 1 wherein the mount boss is located adjacent the header and further includes a surface bonded to a mating surface of the header.
 3. The heat exchanger of claim 2 wherein the surface bonded to the mating surface of the header is shaped to conform to the mating surface of the header.
 4. The heat exchanger of claim 3 wherein the mating surface of the header is cylindrical.
 5. The heat exchanger of claim 1 wherein the mount boss further includes an opening adapted to receive a fastener.
 6. The heat exchanger of claim 5 wherein the opening is threaded.
 7. The heat exchanger of claim 5 wherein the opening extends completely through the mount boss.
 8. The heat exchanger of claim 5 wherein the opening extends perpendicular to the longitudinal tube axis.
 9. The heat exchanger of claim 1 wherein each of the tube runs is a flattened tube having a transverse cross section defined by a pair of spaced, broad side walls connected by a pair of shorter end walls, and each of the contoured surfaces of the mount boss is bonded one of the broad side wall of one of the pair of tube runs.
 10. The heat exchanger of claim 1 further comprising fins extending between the pair of tube runs.
 11. A heat exchanger comprising: a header; a pair of tube runs extending from the header along a longitudinal tube axis to direct a fluid through the heat exchanger; and a mount boss fixed between the pair of tube runs, the mount boss having a pair of shoulders, the shoulders abutting opposite sides of a corresponding one of the tube runs to locate the mount boss during a bonding process.
 12. The heat exchanger of claim 11 wherein the mount boss is located adjacent the header and further includes a surface bonded to a mating surface of the header.
 13. The heat exchanger of claim 12 wherein the surface bonded to the mating surface of the header is shaped to conform to the mating surface of the header.
 14. The heat exchanger of claim 13 wherein the mating surface of the header is cylindrical.
 15. The heat exchanger of claim 11 wherein the mount boss further includes an opening adapted to receive a fastener.
 16. The heat exchanger of claim 15 wherein the opening is threaded.
 17. The heat exchanger of claim 15 wherein the opening extends completely through the mount boss.
 18. The heat exchanger of claim 15 wherein the opening extends perpendicular to the longitudinal tube axis.
 19. The heat exchanger of claim 11 wherein each of the tube runs is a flattened tube having a transverse cross section defined by a pair of spaced, broad side walls connected by a pair of shorter end walls, and the mount boss has a pair of opposite sides, each of the opposite sides bonded to one of the broad side wall of one of the pair of tube runs.
 20. The heat exchanger of claim 11 further comprising fins extending between the pair of tube runs.
 21. A heat exchanger comprising: a pair of spaced headers; a plurality of tube runs extending between the headers along a longitudinal tube axis to direct a fluid through the heat exchanger; fins extending between the tube runs; and a mount boss fixed between an adjacent pair of the tube runs, the mount boss having a pair of oppositely facing contoured surfaces, each of the contoured surfaces bonded to a mating surface of a corresponding one of the tube runs and shaped to conform to the mating surface.
 22. The heat exchanger of claim 21 wherein the mount boss is located adjacent the header and further includes a surface bonded to a mating surface of the header.
 23. The heat exchanger of claim 22 wherein the surface bonded to the mating surface of the header is shaped to conform to the mating surface of the header.
 24. The heat exchanger of claim 23 wherein the mating surface of the header is cylindrical.
 25. The heat exchanger of claim 21 wherein the mount boss further includes an opening adapted to receive a fastener.
 26. The heat exchanger of claim 21 wherein each of the tube runs is a flattened tube having a transverse cross section defined by a pair of spaced, broad side walls connected by a pair of shorter end walls, and each of the contoured surfaces of the mount boss is bonded one of the broad side wall of one of the pair of tube runs.
 27. A heat exchanger comprising: a pair of spaced headers; a plurality of tube runs extending between the headers along a longitudinal tube axis to direct a fluid through the heat exchanger; fins extending between the tube runs; and a mount boss fixed between an adjacent pair of tube runs, the mount boss having a pair of shoulders, the shoulders abutting opposite sides of a corresponding one of the tube runs to locate the mount boss during a bonding process.
 28. The heat exchanger of claim 27 wherein the mount boss is located adjacent the header and further includes a surface bonded to a mating surface of the header.
 29. The heat exchanger of claim 28 wherein the surface bonded to the mating surface of the header is shaped to conform to the mating surface of the header.
 30. The heat exchanger of claim 29 wherein the mating surface of the header is cylindrical.
 31. The heat exchanger of claim 27 wherein the mount boss further includes an opening adapted to receive a fastener.
 32. The heat exchanger of claim 28 wherein each of the tube runs is a flattened tube having a transverse cross section defined by a pair of spaced, broad side walls connected by a pair of shorter end walls, and the mount boss has a pair of opposite sides, each of the opposite sides bonded to one of the broad side wall of one of the pair of tube runs. 